New reliance on methanol could enhance the use of fuel cells for autos, cell phones and computers

Blacksburg, VA, July 30, 2002 –– Using a new twist on fuel cell technology, Jeff Mecham thinks he may be one step closer to assisting the automotive industry make economical use of this energy saving, clean burning alternative to the combustion engine.

Under the auspices of a Small Business Innovation Research (SBIR) grant, Mecham is making significant strides in bringing this highly touted, environmentally friendly technology to the marketplace. His started this work while he was pursuing his doctorate from Virginia Tech’s chemistry department, and he is continuing related work as a full-time employee of one of the University’s spin-off companies, NanoSonic, Inc. of Blacksburg, Va.

The SBIR grant funded Mecham’s exploration of a new polymer electrolyte membrane for direct methanol fuel cell (DMFC) technology that can also be applied to a hydrogen fuel cell.

Mecham’s technical edge in this field is that he works in the relatively new world of nanotechnology, and his company holds the license to nine patents for a modified self-assembly process that has allowed them to manufacture near perfect materials by environmentally benign processes. His novel proton exchange membrane material will be an addition to the company’s technology platforms.

The most commonly used polymer membrane in proton exchange membrane fuel cells is Nafion, a perfluorinated tetrafluorethylene copolymer. First used by NASA during the Gemini space program as its proton exchange membrane material, Nafion is currently widely used in the commercial marketplace, but has some limitations. One problem is its cost -- $800 per square meter. “When you look at the fact that you need 300 to 400 volts to drive a car, and the voltage output of one cell is less than a volt, the required voltage is obtained by connecting individual fuel cells in series to form a fuel cell stack. There is a membrane between each plate, and $800 per square meter mounts up quickly,” Mecham explains.

Another problem with Nafion membranes is their high permeability to methanol. When this occurs, the result is a chemical short circuit of the fuel system. When methanol flows through the membrane material, a chemical short circuit of the fuel system occurs. The new membrane material Mecham is developing is specifically designed to minimize the alcohol permeation problem.

Nafion also softens when operating temperatures exceed 80 ° C, and with the current types of fuel cells, they should be able to operate at temperatures that can run as high as 150 ° C, Mecham says. “By maximizing the operating temperature, catalyst lifetimes are greatly increased.”

Yet another advantage to Mecham’s technique is his ability to precisely control the morphology of the membrane he is developing. Using a specialized new synthesis technique to Mecham’s uniquely designed nanomaterial, he is able to apply layers of materials that are as thin as 0.2mm. Yet, they are still capable of producing the voltage needed for the fuel cell. Mecham believes the true trick will be to manufacture the membrane at less than $50 a square meter, which he predicts can be accomplished.

Automakers and component manufacturers have already spent an estimated $2 billion plus to develop methanol fuel cell vehicles with Daimler-Chrysler, Toyota, General Motors, Nissan, Honda, and Volvo among the largest participants in research and development. As they work to introduce zero emission vehicles that are economically attractive to the consumer, Mecham’s new manufacturing process and his specifically designed membrane would bring the cost down significantly.

The DMFC technology is also viable because of potential application to small electronic devices such as computers and cell phones where power supply lifetimes could be increased by several orders of magnitude. The vast quantity of natural gas ensures the availability of feedstock to produce the methanol needed for a future fleet of DMFC vehicles

Mecham will soon apply for a Phase II SBIR grant to continue his work, and he is currently in negotiations with a major polymer company and one of the Fortune 500 companies with interests in this area.